U.S. patent application number 10/016625 was filed with the patent office on 2002-04-18 for apparatus for slowing down and guiding a signature and method for doing the same.
This patent application is currently assigned to Quad/Tech, Inc.. Invention is credited to d'Agrella, Ingermar S., Kuhne, Eric L., Laatsch, Gary J., Neary, John M., Schaefer, Karl P..
Application Number | 20020043757 10/016625 |
Document ID | / |
Family ID | 22835552 |
Filed Date | 2002-04-18 |
United States Patent
Application |
20020043757 |
Kind Code |
A1 |
d'Agrella, Ingermar S. ; et
al. |
April 18, 2002 |
Apparatus for slowing down and guiding a signature and method for
doing the same
Abstract
An apparatus for decelerating signatures moving in tandem
fashion through sheet processing equipment is provided. A pair of
counter-rotating cams lying in general face-to-face relation along
a travel path of the signatures reach into the travel path of the
signatures to effectively grab the trailing end of each signature
so as to decrease the speed of each signature as the signature
continues or to further processing equipment in the sheet handling
system. Also provided is a guide assembly which increases control
over the signatures during the decelerating process and during
transport of the signatures to further downstream processing
equipment.
Inventors: |
d'Agrella, Ingermar S.;
(Sussex, WI) ; Kuhne, Eric L.; (Big Bend, WI)
; Laatsch, Gary J.; (Germantown, WI) ; Neary, John
M.; (Hartland, WI) ; Schaefer, Karl P.;
(Brookfield, WI) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH, LLP
100 E WISCONSIN AVENUE
MILWAUKEE
WI
53202
US
|
Assignee: |
Quad/Tech, Inc.
Sussex
WI
|
Family ID: |
22835552 |
Appl. No.: |
10/016625 |
Filed: |
December 10, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10016625 |
Dec 10, 2001 |
|
|
|
09223214 |
Dec 30, 1998 |
|
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Current U.S.
Class: |
271/182 ;
271/306 |
Current CPC
Class: |
B65H 2801/21 20130101;
B65H 29/20 20130101; B65H 29/68 20130101; B65H 2701/176 20130101;
B65H 29/12 20130101 |
Class at
Publication: |
271/182 ;
271/306 |
International
Class: |
B65H 029/68 |
Claims
What is claimed is:
1. A signature slow down mechanism for receiving regularly spaced
apart signatures provided along a travel path at a relatively high
speed and for reducing the speed of the signatures, comprising: a
main roller assembly including a shaft adapted for rotation and a
cam member fixedly attached to said shaft, said cam member
including an outwardly protruding cam shaped lobe; and a snubber
cam assembly including a shaft adapted for rotation and a cam
member fixedly attached to said shaft, said cam member including an
outwardly protruding cam shaped lobe, such that as a signature
travels between said main roller assembly and said snubber cam
assembly, said main roller assembly protruding cam lobe lies in
general face-to-face relation with said snubber cam assembly
protruding cam lobe along the travel path in order to effectively
grab a tail end of the signature so as to slow down the speed of
the signature.
2. A signature slow down mechanism according to claim 1, wherein
the speed of the signature is slowed down by about 30 percent.
3. A signature slow down mechanism according to claim 1, further
including a motor which drives said main roller assembly shaft and
said snubber cam assembly shaft.
4. A signature slow down mechanism according to claim 3, wherein
said shafts are driven at a speed such that said respective cam
lobes have a linear speed which is about 30 percent slower than the
linear original speed of the signature.
5. A signature slow down mechanism according to claim 1, further
including a pair of opposed belts circulating in separate endless
loops through said slow down mechanism and confining the signature
therebetween, wherein said belts diverge from a point upstream of
said main roller assembly and said snubber cam assembly such that
said belts effectively release the signature therebetween before
the signature reaches said main roller assembly and said snubber
cam assembly whereby said main roller assembly cam lobe and said
snubber roller assembly cam lobe extend beyond said respective
belts so as to grab the tail end of the signature thereby reducing
the speed of the signature.
6. A signature slow down mechanism according to claim 1, wherein
the signatures travel generally vertically downward along the
travel path between said main roller assembly and said snubber cam
assembly.
7. A signature slow down mechanism according to claim 1, wherein
the signatures move in tandem along the travel path and, wherein
said cam members make one revolution for each signature that
travels between said main roller assembly and said snubber cam
assembly so that said respective cam lobes slow down the signatures
in successive order.
8. A signature slow down mechanism according to claim 1, wherein
said main roller assembly cam lobe includes an exterior lobe
surface made of steel.
9. A signature slow down mechanism according to claim 1, wherein
said main roller assembly cam lobe incudes an exterior lobe surface
having a rubber cover.
10. A signature slow down mechanism according to claim 1, wherein
said snubber cam assembly cam member comprises two halves clamped
together for easy removal and replacement of a worn cam member and
for facilitating positions of said cam member along said respective
shaft in a desired location.
11. A signature slow down mechanism according to claim 1, wherein
said snubber cam assembly cam lobe includes an exterior cam lobe
surface having a rubber cover.
12. A signature slow down mechanism according to claim 1, wherein
said snubber cam assembly cam lobe is made of steel and, wherein
said steel cam lobe includes an exterior cam lobe surface having a
rubber cover molded thereto.
13. A signature slow down mechanism according to claim 1, wherein
said snubber cam assembly cam member is made of rubber or a plastic
type material.
14. A signature slow down mechanism according to claim 5, wherein
said main roller assembly further includes a belt roller located
about said main roller assembly shaft and which is independently
rotatable about said main roller assembly shaft irrespective of the
rotation of said main roller assembly shaft and, wherein one of
said belts is in operative engagement with said belt roller.
15. A signature slow down mechanism according to claim 14, wherein
said belt roller mounts to a bearing which is secured to said main
roller assembly shaft thereby allowing relative rotational motion
between said main roller assembly cam member and said belt
roller.
16. A signature slow down mechanism according to claim 14, wherein
said belts circulate in said separate endless loops at a given
rotational speed, wherein said belt roller is driven by one of said
belts and, wherein said cam members of said main roller assembly
and said snubber cam assembly are driven at a speed such that said
respective cam lobes have a linear speed that is slower than the
speed of said belts.
17. A signature slow down mechanism according to claim 1, wherein
said main roller assembly further includes: a housing which
surrounds one end and a portion of said main roller assembly shaft;
at least one bearing supported by said housing and which supports
said main roller assembly shaft; an input drive pulley attached to
said one end of said main roller assembly shaft; and wherein said
snubber cam assembly further includes: a pair of bearings affixed
to opposite ends of said snubber cam assembly shaft and which
support said snubber cam assembly shaft; a pulley attached to one
end of said snubber cam assembly shaft; and wherein, said slow down
mechanism further includes a pivot shaft assembly comprising: a
shaft adapted for rotation; a housing which surrounds one end and a
portion of said pivot assembly shaft; at least one bearing
supported by said housing and which supports said pivot assembly
shaft; an input drive pulley attached to said one end of said pivot
assembly shaft; a second pulley attached to the other end of said
pivot assembly shaft; and wherein, said slow down mechanism further
includes: a pair of swing arms which support said bearings of said
snubber cam assembly and which house a second pair of bearings
which support said shaft of said pivot shaft assembly; a timing
belt engaging said snubber cam assembly pulley and said pivot shaft
assembly second pulley; a second timing belt engaging said main
roller assembly input drive pulley and said pivot shaft assembly
input drive pulley; and a motor having an output pulley mounted to
an output shaft of said motor such that said second timing belt
engages said motor output pulley, said motor causing said second
timing belt to drive said pivot shaft assembly shaft and said main
roller assembly shaft, said pivot shaft assembly shaft causing said
snubber cam assembly shaft to rotate by virtue of said timing belt
integrally connected to both, said second timing belt being
arranged to rotate said pivot shaft assembly shaft and said main
roller assembly shaft in opposite directions so that said
respective cam lobes of said main roller assembly and said snubber
cam assembly turn in the direction the signatures travel
therethrough.
18. A signature slow down mechanism according to claim 17, further
including: an external first take up roller positioned adjacent
said timing belt which is adjustable to take up any slack in said
timing belt; and an internal second take up roller positioned
adjacent said second timing belt which is also adjustable in order
to take up any slack in said second timing belt.
19. A signature slow down mechanism according to claim 1, further
comprising: a swing arm connected to one end of said snubber cam
assembly shaft; and an air cylinder connected to said swing arm,
said air cylinder attached to a machine frame which surrounds said
slow down mechanism, said air cylinder operable to rotate said
swing arm such that said snubber cam assembly is movable with
respect to said main roller assembly so as to enable possible jams
to be cleared.
20. A signature slow down mechanism according to claim 19, wherein
said air cylinder further includes an adjustment mechanism to
adjust a gap between said main roller assembly and said snubber cam
assembly so as to increase or reduce the gripping force of said
respective cam lobes against a signature.
21. A signature slow down mechanism according to claim 17, further
comprising: a pair of air cylinders, one air cylinder connected to
one swing arm and said other air cylinder connected to said other
swing arm, said air cylinders supported by a machine frame which
surrounds said slow down mechanism, said air cylinders operable to
move said swing arm in order to open or close a space between said
main roller assembly and said snubber cam assembly allowing
possible jams to be cleared.
22. A signature slow down mechanism according to claim 21, wherein
said air cylinders include respective threaded knobs mounted on
respective rear rod ends of a double rod end in each air cylinder,
said knobs capable of adjusting a gap between said main roller
assembly and said snubber cam assembly so as to increase or
decrease the gripping force of said respective cam lobes against
the signature traveling therethrough.
23. A signature delivery system comprising: a signature slow down
mechanism for decelerating signatures delivered thereto in tandem
at an original speed along a travel path; a first group and a
second group of belts circulating in separate endless loops through
said signature slow down mechanism, said groups of belts lying in
general face-to-face relation along a travel path of the signatures
and confining the signatures therebetween; a signature eject roller
positioned downstream of said slow down mechanism, said eject
roller having a plurality of spaced apart grooves with raised
surfaces located respectively therebetween, wherein said first
group of said belts engages said eject roller such that each belt
in said first group of belts travels in respective grooves of said
plurality of grooves in said eject roller, wherein as the
signatures travel down the path, said raised surfaces in said eject
roller are capable of contacting the signatures so as to send the
signatures on to a next processing step in order to prevent the
signatures from following said first group of belts in said endless
loop to prevent jams in said delivery system.
24. A folder apparatus according to claim 23, further comprising a
second signature eject roller positioned downstream of said slow
down mechanism, said second eject roller having a plurality of
spaced apart grooves with raised surfaces located respectively
therebetween, wherein said second group of said belts engages said
second eject roller such that each belt in said second group of
belts travels in respective grooves of said plurality of grooves in
said second eject roller wherein, as the signatures travel down the
path, said raised surfaces in said second eject roller are capable
of contacting the signatures so as to send the signatures on to the
next processing step in order to prevent the signatures from
following said second group of belts in said endless loop to
prevent jams in said delivery system.
25. A signature delivery system comprising: a signature slow down
mechanism for decelerating signatures delivered at an original
speed along a travel path; and an air blowing system positioned
downstream of said signature slow down mechanism, said air blowing
system expelling air so as to assist in guiding the signatures into
further downstream equipment and so as to prevent the signatures
from opening if the signatures are folded signatures so as to
reduce the likelihood of damage occurring to the signatures.
26. A signature delivery system according to claim 25, wherein said
air blowing system expels air parallel with the travel path of the
signatures.
27. A signature delivery system according to claim 25, wherein said
air blowing system expels air at an angle into the travel path of
the signatures.
28. A signature delivery system according to claim 25, wherein said
air blowing system includes an air bar having spaced apart holes,
said air bar positioned adjacent the signature travel path to expel
air through said holes parallel with the travel path at an angle to
the travel path.
29. A signature delivery system according to claim 25, wherein said
air blowing system includes a pair of air tubes having spaced apart
holes, said air tubes positioned adjacent the signature travel path
such that air expelled through one of said tubes is parallel with
the travel path of the signatures and air expelled through said
other tube is at an angle to the travel path of the signatures.
30. A signature delivery system for transporting regularly spaced
apart signatures delivered along a travel path at an original speed
which comprises: a diverter mechanism for alternately diverting
successive signatures to one of two collation paths; a main roller
assembly including a shaft adapted for rotation and a cam member
fixedly attached to said shaft, said cam member including an
outwardly protruding cam shaped lobe; a snubber cam assembly
including a shaft adapted for rotation and a cam member fixedly
attached to said shaft, said cam member including an outwardly
protruding cam shaped lobe; a first group and a second group of
opposed belts circulating in separate endless loops at a given
rotational speed through said main roller assembly and said snubber
cam assembly and confining the signatures therebetween, wherein
said groups of belts diverge from a point upstream of said main
roller assembly and said snubber cam assembly such that said groups
of belts effectively release the signature therebetween before the
signature reaches said main roller assembly and said snubber cam
assembly whereby said main roller assembly protruding cam lobe lies
in general face-to-face relation with said snubber roller assembly
protruding cam lobe along the travel path in order to effectively
grab a tail end of the signatures traveling therethrough so as to
slow down the speed of the signature; a belt roller mounted about
said main roller assembly shaft and which is independently
rotatable about said shaft irrespective of the rotation of said
shaft, wherein one of said group of opposed belts is in operative
engagement with said belt roller, said belt roller driven by said
one of said group of opposed belts, said cam members of said main
roller assembly and said snubber cam assembly driven at a speed
such that said respective cam lobes have a linear speed that is
slower than the speed of said groups of belts; a first signature
eject roller positioned downstream of said main roller assembly and
said snubber cam assembly, said first eject roller having a
plurality of spaced apart grooves with raised surfaces located
respectively therebetween, wherein said first group of said belts
engages said first eject roller such that each belt in said first
group of belts travels in respective grooves of said plurality of
grooves in said first eject roller, wherein, as the signatures
travel down the path, said raised surfaces in said eject roller are
capable of contacting the signatures so as to send the signatures
on to a next processing step in order to prevent the signatures
from following said first group of belts in said endless loop to
prevent jams; a second signature eject roller positioned downstream
of said main roller assembly and said snubber cam assembly, said
second eject roller having a plurality of spaced apart grooves with
raised surfaces located respectively therebetween, wherein said
second group of said belts engages said second eject roller such
that each belt in said second group of belts travels in respective
grooves of said plurality of grooves in said second eject roller
wherein, as the signatures travel down the path, said raised
surfaces in said second eject roller are capable of contacting the
signatures so as to send the signatures on to the next processing
step in order to prevent the signatures from following said second
group of belts in said endless loop to prevent jams; and an air
blowing system positioned downstream of said main roller assembly
and said snubber cam assembly, said air blowing system expelling
air so as to assist in guiding the signatures into further
processing equipment and so as to prevent the signatures from
opening if the signatures are folded signatures so as to reduce the
likelihood of damage occurring to the signatures.
31. A signature delivery system according to claim 30, further
including: a belt diverging roll positioned upstream of said main
roller assembly and said snubber cam assembly and adjacent one of
said groups of belts, such that said belt diverging roll is capable
of adjusting the diverging point of said groups of belts.
32. A signature delivery system according to claim 30, wherein said
main roller assembly and said snubber cam assembly are of a
cantilever design and attached to a machine wall which surrounds
said delivery system.
33. A method for transporting regularly spaced apart signatures
traveling at an original speed along a travel path through a sheet
processing system, which comprises: delivering the signatures to a
diverter mechanism; diverting the signatures to one of a plurality
of collation paths; guiding the signatures in tandem to a slow down
mechanism; advancing the signatures one by one along the slow down
mechanism; decelerating the speed of the signatures as each
signature travels along the slow down mechanism by grabbing a tail
end of each signature with said slow down mechanism; and feeding
the signatures in tandem to further processing equipment.
34. A method for transporting signatures according to claim 33,
wherein said diverting step includes diverting a first signature to
a first collation path, diverting a second signature to another
collation path and so on, until another signature is diverted to
said first collation path whereby said diverting step repeats
itself.
35. A method for transporting signatures according to claim 34,
wherein for each collation path, a separate slow down mechanism is
provided.
36. A method for transporting signatures according to claim 34,
wherein the slow down mechanism includes at least a pair of
rotating cams lying in general face-to-face relation.
37. A method for transporting signatures according to claim 35,
wherein each of the slow down mechanisms includes at least a pair
of rotating cams lying in general face-to-face relation.
38. A method for transporting signatures according to claim 33,
further comprising the steps of: circulating a first group and a
second group of diverter belts in separate endless loops through
the sheet processing system, said first group of diverter belts and
said second group of diverter belts lying in general face-to-face
relation along the travel path confining signatures therebetween
for transport to said diverter mechanism, said groups of diverter
belts diverging from a point upstream of said diverter mechanism
along distinct collation paths; circulating a first group of
collator belts in separate endless loops lying in general
face-to-face relation with said first group of diverter belts along
one of said collation paths, said first group of belts diverging
from a point upstream of said slow down mechanism, the signatures
being confined by said first group of belts as the signatures
travel past said slow down mechanism.
39. A method for transporting signatures through a folder according
to claim 38, wherein said slow down mechanism includes at least a
pair of rotating cams having respective outwardly protruding cam
lobes lying in general face-to-face relation such that said cam
lobes extend between said respective first groups of belts in order
to grab the tail end of each signature as the signatures move
toward said processing equipment.
40. A method for transporting sheets delivered from a high speed
printing press at an original speed to a folder wherein the sheets
are transformed into a plurality of individual signatures which
travel down a path through the folder, which comprises: delivering
the signatures in tandem order to a slow down mechanism; sensing
location of a leading edge of each signature prior to the leading
edge reaching said slow down mechanism; phasing said slow down
mechanism with respect to each signature based on said sensed
location of the leading edge of each signature such that said slow
down mechanism grabs a trailing end of each signature in order to
decrease the speed of each signature; and feeding the signatures in
tandem into a fan delivery device which is phased to be in proper
position based on said sensed location of the leading edge of each
signature.
Description
FIELD OF THE INVENTION
[0001] The present invention relates, generally, to sheet
processing equipment for transporting signatures moving in serial
fashion along a path to one of a plurality of collation paths and,
more particularly, to sheet processing equipment for collation of
printed signatures to be used in the binding of a publication such
as a magazine or a newspaper. The present invention relates to an
apparatus for decelerating substantially evenly spaced apart
successive signatures found in a stream of fast moving signatures
for delivery of the signatures to a subsequent process such as a
rotary fan delivery device. The present invention also relates to
an apparatus for guiding successive signatures from a slow down
mechanism of the foregoing kind to a downstream destination such as
a rotary fan delivery device. The present invention provides an
improved signature delivery system for a high speed printing press
which allows for increased operating speeds with fewer jams while,
at the same time, reducing or preventing damage to the signatures
as the signatures travel through sheet processing equipment.
BACKGROUND OF THE INVENTION
[0002] Sheet processing equipment contemplated herein may range
from apparatus associated with an office copier, to sheet or web
handling devices employed in the manufacture of paperboard
articles, to sheet processing equipment specifically adapted to
process signatures to be used in binding or otherwise assembling
books, magazines or newspapers. Each of these environments presents
a somewhat different challenge in designing an efficient collator
or delivery system, but the same objective applies to the entire
class of apparatus, namely, accurately routing selected flexible
webs or ribbon sections along a desired collation path to achieve a
desired order.
[0003] In the printing industry, an image is repeatedly printed on
a continuous web or substrate such as paper. The ink is dried by
running the web through curing ovens. In a typical printing
process, the web is subsequently slit (in the longitudinal
direction which is the direction of web movement) to produce a
plurality of continuous ribbons. The ribbons are aligned one on top
of the other, folded longitudinally, and then cut laterally to
produce a plurality of multi-paged, approximately page length web
segments, termed signatures. A signature can also be one printed
sheet of paper that has or has not been folded. It is often
desirable to transport successive signatures in different
directions along different paths in order to increase the overall
operating speed and versatility of the printing process. In
general, a sheet diverter operates to route fast moving signatures
along a desired one of a plurality of paths as the signatures
continue on to the next step in the signature processing
system.
[0004] Printing press systems are operable at high speeds,
typically in excess of 2,000-3,000 feet per minute (fpm). It is
often desirable to run printing press equipment at the highest
speeds possible in order to produce as many printed products as
possible in a given amount of time. Because printing presses
operate at high speeds, it is usually, if not always, necessary to
reduce the speed of the signatures in the delivery system in order
to shingle and to square the signatures and eventually stack the
signatures. Various delivery systems for decelerating and shingling
signatures are set forth in the prior art.
SUMMARY OF THE INVENTION
[0005] A system which employs a rotary fan delivery system is found
after signature decelerating equipment to individually collect the
signatures and subsequently pass each signature to a conveyor, such
as a shingling conveyor. Generally, signatures are caused to fall
or move into a receptive slot in the rotating fan-like delivery
means. As the rotary fan rotates, the signatures fall out one after
the other typically onto a slow moving conveyor in an overlying or
shingled arrangement. Without signature decelerating equipment, in
order to avoid damage to the signatures as the signatures are
thrown into the respective slots of the rotary fan device, the
speed of each signature must be generally slowed down by running
the printing press and folder at a slower rate of speed so that the
impact force of the leading edge of the signature against a dead
end surface of the slot is reduced. Thus, without a slow down
mechanism, reduced operating speeds limit the overall output of the
printing system.
[0006] A problem which may occur when using a rotary fan delivery
system concerns adequately controlling the path of each signature
as the signatures are transferred from a slow down device to the
rotary fan delivery system. In such systems, signatures generally
fall from the slow down device to the rotary fan device. Stated
differently, the signatures may be unsupported or unguided during
this transfer step. Unsupported signatures have a tendency to
freely flap, fold over, tear or be damaged in other different ways,
or have a tendency to move to the wrong destination. The greater
the distance between a slow down device and a fan delivery system,
the more likely an unsupported signature will be damaged as it
enters or attempts to enter the fan delivery system thereby causing
jams in the overall process resulting in down time and repair
expenses.
[0007] Yet another problem of utilizing a delivery system concerns
guiding the signatures from a slow down mechanism to a subsequent
processing device. Often, when a signature travels through a
processing system between two signature transport tapes, the
signature may tend to cling to one or both of the two tapes during
the transition stage, instead of continuing on in a straight or
substantially straight path to subsequent processing equipment.
When a signature improperly follows a tape path and travels to the
wrong place in the processing system, a jam can occur which results
in the shut down of the entire printing production system until the
jam is cleared.
[0008] Still another problem of such a delivery system concerns
correctly timing the transfer of the signatures from one step in
the printing process, such as a slow down step, to a subsequent
step, such as a fan delivery step. If a respective signature slot
in a rotary fan delivery device is not properly aligned with a
signature emerging from a slow down mechanism at the appropriate
time, a signature will be directed at the fan delivery device in
such a way that the signature will not properly enter the rotary
fan device which may cause a jam in the overall operation.
[0009] Although the problems described above generally correlate to
a processing system which employs a rotary fan delivery device, the
same or similar problems can occur in other delivery systems which
utilize slow down mechanisms followed by other known processing
equipment. The present invention may be utilized in various
delivery systems for decelerating signatures and transferring the
signatures to further processing equipment such as, for example,
shingling devices or stackers, known to those skilled in the
art.
[0010] Accordingly, there is a need for a sheet processing system
that is capable of operating at high speeds, e.g., speeds in excess
of 2,500-3,000 fpm and above, and yet is also capable of providing
signatures that are acceptable in quality. What is needed is a
delivery system which reduces the speed of signatures traveling
through the processing system while allowing for an increased
overall operating speed of the sheet processing system. What is
also needed is a sheet processing system which increases control
over signatures during a decelerating process and during transport
of the signatures to a subsequent processing step.
[0011] In accordance with one embodiment of the present invention,
a sheet diverter receives a fast moving stream of regularly spaced
apart signatures from a sheet processing system. The sheet diverter
sends the signatures down one of a plurality of collation paths. A
signature slow down mechanism is positioned within the collation
path such that as a signature travels down the collation path, the
signature slow down mechanism grabs a tail end of the signature to
slow down the speed of the signature. A pair of rotating cam lobes
lying in general face-to-face relation along the collation path
effectively reach into the collation path at the appropriate moment
to grab the trailing end of the signature therebetween.
[0012] In a preferred embodiment, a pair of opposed tapes
circulating in separate endless loops through the slow down
mechanism and confining a signature therebetween, deliver the
signature to the slow down mechanism which comprises a pair of
counter-rotating independently driven roller or cam assemblies. The
slow down mechanism has a lineal speed that is less than the lineal
speed of the signatures so as to reduce the speed of the signatures
as they are grabbed by the slow down mechanism.
[0013] In accordance with another embodiment of the present
invention, regularly spaced apart signatures traveling at an
original speed along a travel path are alternately diverted into a
selected one of a plurality of collation paths to create a larger
space between successive signatures in the selected paths after
which the signatures are decelerated prior to being transferred to
a subsequent process. The signatures are decelerated such that the
leading edge of a trailing signature traveling down a selected one
of the paths of signatures does not contact the trailing edge of a
leading signature traveling down the same path as the leading
signature is slowed down and the trailing signature continues on
toward the slow down device.
[0014] In accordance with yet another embodiment of the present
invention, a signature slow down mechanism is provided to
decelerate the speed of individual signatures traveling along a
path on their way to a further processing step in an overall sheet
handling system. The slow down mechanism is positioned at the end
of a collation path and is designed to be positioned as close as
possible to the next device in the sheet handling system so as to
increase control over the signatures as the signatures are
transferred from one piece of equipment to another.
[0015] In accordance with still another embodiment of the present
invention, a signature slow down assembly is provided along a path
in which signatures travel on their way to further processing
equipment in an overall sheet handling system. The signature slow
down mechanism is capable of being opened and closed with respect
to the path of the traveling signatures in order to clear away jams
which may occur in the sheet handling system prior to, in or near,
the signature slow down assembly. In addition, for those types of
products produced in a printing press system which do not require
the use of a slow down mechanism or need the advantages provided
thereby, the adjustable, movable slow down mechanism can be, in
effect, disengaged by moving the slow down device away from the
signature path.
[0016] In a preferred embodiment, the signature slow down mechanism
is capable of further adjustment so as to increase or decrease the
gripping force applied to a signature as the signature is slowed
down by the slow down mechanism.
[0017] In accordance with another embodiment of the present
invention, a method for transporting signatures traveling at an
original speed along a travel path through a sheet processing
system is provided. The signatures are delivered to a slow down
mechanism in which the speed of the signatures is reduced. The
signatures are then fed to a further processing step. The original
speed and position of the signatures, the position and operation of
the slow down mechanism and the position and operation of the
further processing equipment are phased in relation to each other
so as to prevent or minimize damage to the signatures and increase
the overall operating speed of the processing system.
[0018] In a further embodiment of the present invention, a
signature guiding device is positioned intermediate of a signature
slow down mechanism and a further delivery device. The guiding
device is designed to prevent a signature from traveling along a
wrong path as the signature is transferred from one device to the
next. Preferably, the guiding device comprises a stripping
signature eject idler roller which effectively strips a signature
from a group of belts traveling in an endless loop in a processing
system allowing the signature to properly continue on to the next
step. An air blowing system may be used in combination with the
eject idler roller or alternatively, by itself, to expel air in an
appropriate manner thereby assisting in the control over the
signatures as the signatures move from one device to another.
[0019] Accordingly, it is a general feature of the present
invention to provide an apparatus for receipt of signatures from a
high speed printing press and for slowing down the signatures to
decrease signature damage, reduce jams and increase the overall
operating speed of a sheet processing system.
[0020] Another feature of the invention is to provide a signature
delivery system which is useful for a wide range of paper types and
products over a wide range of press speeds and which is also useful
in combination with diverter systems and signature discharge
systems without significant modification to those systems.
[0021] Yet another feature of the present invention is to provide
an improved signature delivery system which is easy to operate,
easy to service, economical to manufacture and is relatively simple
to construct and assemble.
[0022] Still another feature of the present invention is to provide
a sheet processing system which increases control over signatures
as the signatures travel from one processing step to another
thereby decreasing signature damage, jams in the operating
equipment and increasing overall speed of a printing press
operation.
[0023] A further feature of the present invention is to provide a
slow down mechanism that provides consistent, substantially
non-varying signature transfer timing to subsequent processing
equipment in a sheet handling system such as, for example, a rotary
fan delivery system.
[0024] Yet, a further feature of the present invention is to
effectively transfer signatures from a slow down mechanism to
subsequent equipment in a sheet processing system thereby achieving
the advantages provided for herein.
[0025] Other features and advantages of the invention will become
apparent to those skilled in the art upon review of the following
detailed description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a partial schematic diagram of a pinless folder in
which various features of the present invention may be
employed.
[0027] FIG. 2 is a partial cross-sectional view taken generally
along line II-II of FIG. 1 showing a signature delivery system
according to the present invention with certain parts added and
removed for clarity.
[0028] FIG. 3 is a perspective view showing in clearer detail a
signature slow down mechanism of FIGS. 1-2.
[0029] FIG. 4 is another perspective view showing even more detail
of another slow down mechanism similar to that shown in FIGS.
1-3.
[0030] FIG. 5 is an illustrative view of a signature traveling
through a signature delivery system according to the present
invention and moving on to further processing equipment such as a
rotary fan delivery device.
[0031] FIG. 6 is a perspective view of certain components of a
signature guide assembly shown in FIG. 5.
[0032] Before the embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangements
of components set forth in the following description or illustrated
in the drawings. The invention is capable of other embodiments and
of being practiced or of being carried out in various ways. Also,
it is to be understood that the phraseology and terminology used
herein is for the purpose of description and should not be regarded
as limiting. The use of "including" and "comprising" and variations
thereof herein is meant to encompass the items listed thereafter
and equivalents thereof as well as additional items. The use of
"consisting of" and variations thereof herein is meant to encompass
only the items listed thereafter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Illustrated in FIG. 1 of the drawings is a partial schematic
diagram of a pinless folder which is a part of a high speed
printing press (not shown). A typical folder includes a forming
section, a driving section, a cutting section, a diverting section
and a collating section. The invention described herein is
primarily directed to apparatus and methods found near the end of a
collating section and upstream of further processing equipment in
an overall printing press operation. A description of a typical
pinless folder is found in U.S. Pat. No. 4,729,282, assigned to
Quad/Tech, Inc., of Pewaukee, Wis., and is hereby incorporated by
reference. Shown in FIG. 1, among other things, is a delivery
system 10 according to the present invention.
[0034] Once a sheet or web has been transformed into a plurality of
individual signatures as described, for example, in the '282
patent, successive signatures enter a diverter section 12 including
a pair of oscillating diverter rolls 13 along a diverter path 14.
The signatures are led serially via opposed tapes or belts 16 and
18 to a diverter 20. The diverter 20 alternately deflects
successive signatures to a selected one of a plurality of collation
paths 22 or 24. The signatures enter an appropriate collating
section 26 or 28 and are fed along one of the collation paths 22 or
24 to a destination such as a rotary fan delivery device 30 and
subsequently to a conveyor (not shown), such as a shingling
conveyor as is known in the art. Prior to reaching the rotary fan
delivery device 30, the signatures travel through the delivery
system 10.
[0035] The signatures are routed along the diverter path 14 and to
a selected one of the collation paths 22 or 24 under the control of
a signature controller means including a primary signature
controller 32 and secondary signature controllers 34 and 36.
Preferably, the distance through the diverter section 12 between
the primary signature controller 32 and respective secondary
signature controllers 34 and 36 is less than the length of the
signature to be diverted. In this way, the selected secondary
signature controller 34 or 36 assumes control of the leading edge
of a signature before the primary signature controller 32 releases
control of the trailing edge of the same signature.
[0036] The primary 32 and secondary signature controllers 34 and 36
include one or both of opposed face-to-face belts or tapes 16 and
18 disposed over rollers in endless belt configurations. The
primary signature controller 32 includes the first diverter belt 16
and the second diverter belt 18 which circulate in separate
continuous loops in the directions shown by the arrows in FIG. 1
and are joined at a nip between a set of idler rollers 38 near the
outfeed of a cutting section (not shown), as such is described in
the '282 patent. Drive rollers 40 and 42 drive the diverter belts
16 and 18 respectively about, among other certain components in the
separate continuous loops, idler rollers 38, a plurality of idler
rollers 44, trailing edge signature slow down mechanisms 46 of
delivery systems 10, and idler rollers 48 and 50. The diverter
belts 16 and 18 are also driven around guide idler rollers 52. Both
diverter belts 16 and 18 are driven by respective drive rollers 40
and 42 at the same speed, which typically is from 8% to 15% faster
than the paper speed through the printing press. The faster speed
of the belts 16 and 18 causes a gap to occur between successive
signatures as the signatures flow serially down path 14 between the
diverter belts 16 and 18. Preferably, for a signature having a
length of about 10.875 inches, the gap between successive
signatures is approximately between about 1-2 inches. Preferably,
signatures travel generally vertically downward through the
diverter section 12 alternately along collation paths 22 or 24 so
that the signatures are bent as little as possible to avoid certain
damage to the signatures. Since the signatures are alternately
deflected and routed to one of a plurality of collation paths, the
gap between successive signatures traveling down each collation
path increases by at least the amount of the length of the
signatures, typically, 10.875 inches. Therefore, the total gap
between signatures traveling down a collation path includes the
original gap length between successive signatures of about 1-2
inches, plus the length of a signature which is diverted to another
collation path, plus the original gap length between what was
originally successive signatures of about 1-2 inches. As will be
further explained below, the gap between successive signatures in
the collation paths, is one aspect of the present invention which
assists in the operation of a slow down device according to that
described herein.
[0037] The primary signature controller 32 includes a soft nip 54
defined by an idler roller 56 and an abaxially disposed idler
roller 58. The rollers 56 and 58 cause pressure between diverter
belts 16 and 18 as these belts follow the diverter path 14 through
the soft nip 54. The soft nip 54 compressively captures and
positively transports a signature that passes therethrough. Located
upstream of the primary signature controller 32 is an idler roll 60
which also helps direct the signatures through the diverter section
12.
[0038] The secondary signature controllers 34 and 36 include a
first collator belt or tape 62 and a second collator belt or tape
64, respectively, which both circulate in separate continuous loops
in the directions shown by the arrows in FIG. 1. The opposed
collator belts 62 and 64 respectively share common paths with the
diverter belts 16 and 18 along the collation paths 22 and 24,
beginning downstream of the diverter 20. In particular, collator
belt 62 is transported around idler rollers 52 and 66, roll 68 of
the respective trailing edge signature slow down mechanism 46,
idler roller 70, drive roll 72 and idler roll 74. Collator belt 64
is transported around idler roller 52, snubber roller 76 of the
respective trailing edge signature slow down mechanism 46, idler
rollers 78, 80 and 82, drive roll 84, and idler roll 86. Idler
rollers 88 and 90 also define the paths of the collator belts 62
and 64. Rolls 70 and 82 are belt take-up rolls and are operable to
adjust the tension in each belt loop of belts 62 and 64. Rolls 72
and 84 drive belts 62 and 64, respectively, around their continuous
loops. The tension of diverter belts 16 and 18 can also be adjusted
with belt take-up rollers A and B, which are connected via a
pivotable lever arm to an air actuator that applies adjustable
pressure to the belts 16 and 18 as illustrated. Since the tension
in all four belts can be adjusted, adjustable pressure between
opposed belts results to positively hold and transport signatures
at tape speeds. Belts 16 and 18 are driven at the same speed as
belts 62 and 64 through the use of timing belts and timing pulleys
(not shown), such timing belts and timing pulleys generally known
to those skilled in the art. The diameter of drive rolls 40 and 42
for the diverter belts 16 and 18 and the diameter of drive rolls 72
and 84 for the collator tapes 62 and 64 can be the same diameter so
that the belts 16 and 18 and tapes 62 and 64 move at the same speed
as the respective drive rolls rotate at the same rpm. However, it
has been discovered that over the common paths traveled by belts 16
and 18 and tapes 62 and 64, respectively, as a result of the
different paths traveled by the belts and tapes, the wrap angles
around the idlers in the noted paths, the tension applied to the
belts and tapes, the tendency for the belts and tapes to stretch
and/or creep, it has been determined that over the common paths
traveled by belts 16 and 18 and tapes 62 and 64, the belts and
tapes travel different distances for the same degree of rotation of
the respective drive rolls. Therefore, preferably, in order to
account for the difference in distance traveled by the diverter
belts 16 and 18 and collator belts 62 and 64, the drive rollers 72
and 84 are made larger in diameter than drive rollers 40 and
42.
[0039] The secondary signature controller 34 includes a soft nip 92
defined by idler roller 74 operating with the abaxially disposed
idler roller 94, the diverter belt 16 and the collator belt 62.
Similarly, the secondary signature controller 36 includes a soft
nip 96 defined by idler roller 86 operating with the abaxially
disposed idler roller 98, the diverter belt 18 and the collator
belt 64.
[0040] Preferably, in a folder such as that shown in FIG. 1, it is
contemplated that four signature delivery systems, two in front and
two in back, will be used. FIG. 1 shows a front left-hand signature
delivery system 10 and a front right-hand signature delivery system
10. Not shown are the back left-hand and back right-hand signature
delivery systems which lie generally adjacent to or directly behind
the respective front signature delivery systems as such are
arranged in the folder. Certain elements of the front left-hand
signature delivery system are shown in FIG. 2 and an adjacent back
left-hand signature delivery system is shown cut away. As
illustrated in FIG. 1, it is contemplated that individual
signatures are fed to a rotary fan delivery device 30 such as a
rotary fan. Generally, there are the same number of fan devices as
there are signature slow down devices. Other processing equipment
can be used in place of the rotary fan delivery system in
accordance with the principles of the subject invention. Each slow
down mechanism 46 of a respective delivery system 10 is driven by
its own individual motor whose timing phase relationship to
signature arrival can be advanced or retarded as the situation
requires, the details of which will be explained below. When
utilized, each rotary fan is mounted on a shaft which is also
driven by individual motors whose timing can be advanced or
retarded so that the rotary fan pockets can be properly positioned
in time relative to each signature slow down mechanism and the fan
pocket injected signature. The slow down mechanism described herein
slows down the original speed of the signatures before the
signatures reach further processing equipment such as the rotary
fan device.
[0041] The front left-hand signature slow down mechanism 46 shown
in FIG. 1 is basically the same as the front right-hand signature
slow down mechanism 46 shown in FIG. 1 and works in similar fashion
except that the front right-hand signature slow down mechanism is
located vertically above the front left-hand signature slow down
mechanism because of the difference in the location of the two
rotating fan buckets 30. The two fan buckets 30 are spaced
horizontally apart and at different heights because a pair of
shingle conveyors (not shown) remove the product on the right-hand
side of the machine and are placed one over the top of the other,
as generally understood by those skilled in the art.
[0042] The other signature slow down mechanisms are, for all
practical purposes, the same as the front left-hand signature slow
down mechanism except for different mounting assemblies used to
attach the signature delivery systems and components thereof to the
proper framework in the folder. As such, only the front left-hand
signature slow down mechanism will be explained in reference to
most of the figures. The back left-hand signature slow down
mechanism is shown in FIG. 4 to provide a different perspective in
terms of the present invention.
[0043] Considering again FIG. 1, signatures traveling down the
collation path 22 downstream of the diverter 20 are held between
opposed belts 16 and 62 which firmly hold the signatures and
positively transport the signatures on through the folder. The
signatures approach idler roll 66 which generally represents the
beginning of the signature delivery system 10. Belts 16 and 62
start to diverge in linear fashion as they continue through the
signature delivery system 10 (see FIG. 5). In other words,
downstream of idler roll 66, the belts 16 and 62 effectively let go
of the signatures so that the signature slow down mechanism 46 can
reduce the speed of the signatures as will be more fully explained
below.
[0044] The signature delivery system 10, according to the present
invention, illustratively shown in FIG. 1, and more completely
shown in FIG. 2, includes one or more of the following components:
a lead-in idler roller 66, a signature slow down mechanism 46 which
includes a main roller assembly 100 and a snubber cam assembly 102,
a pivot shaft assembly 104, an air cylinder assembly 106, a
signature guide assembly 108 and a drive system 110.
[0045] With reference to FIG. 2, the main roller assembly 100
includes a housing 112 having a flange 113 which mounts to a
machine side framework 114 with bolts 116. A shaft 118 extends
through the housing 112 and is supported by at least one bearing
120 which is supported by the housing 112. Pulley 122 is attached
to one end of the shaft 118 which enables shaft 118 to rotate by
virtue of connection with the drive system 110 fully described
below. Spaced apart main roller assembly cam members 124 are
fixedly attached to shaft 118 with a key 126 (FIG. 5) and set screw
128. Each main roller assembly cam member 124 includes an outwardly
protruding cam-shaped lobe 130 (FIG. 5), the function of which will
be made clear below. Spaced between each main roller assembly cam
member 124 is a respective tape or belt idler roller 132 each of
which rotates on respective bearings 134 which are secured to shaft
118. A set collar (not shown) may cap the other end of shaft 118 in
order to secure cam members 124 and tape rollers 132 in place. A
standard nut and thread combination (not shown) could also be used
to cap the other end of shaft 118 to secure the proper components
in place.
[0046] With continued reference to FIG. 2, the snubber cam assembly
102 includes a shaft 138 upon which are mounted spaced apart
snubber cam assembly cam members 140 which are preferably composed
of two halves 142 and 144 (FIG. 5). The two halves 142 and 144 are
held together with screws 146 and fixed to shaft 138 via keys 148
(FIG. 5). Snubber cam members 140 include outwardly protruding
cam-shaped lobes 150 (FIG. 5). According to the present invention,
snubber cam members 140 cooperate with main roller cam members 124
to slow down signatures traveling therebetween, as will be further
explained herein. The lobes 150 of snubber cam members 140 are
preferably made of steel covered with a layer of hard rubber that
is molded to the steel. Snubber cam members 140 are made of a split
construction (FIG. 5) so that they can be easily removed or added
to shaft 138 without much other assembly or disassembly required.
If a snubber cam member 140 wears out due to use, it can be easily
replaced with a new snubber cam member. Also, snubber cam members
140, because of their split construction, can easily be moved to
different spots on the shaft 138 as desired. For example, depending
on the number of desired snubber cam members 140, the snubber cam
members 140 can easily be relocated to proper positions along shaft
138. Main roller assembly cam members 124 are preferably of a
single construction and made from steel, but if desired, could also
be of a split construction and incorporate rubber covered steel
lobes, similar to snubber cam members 140. The snubber shaft 138 is
supported by a pair of bearings 152 and 154 at opposite ends
thereof and which are mounted in respective swing arms 156 and 158.
Timing pulley 160 is attached to one end of the snubber shaft 138.
Timing pulley 160 enables shaft 138 to rotate as a result of
connection with a belt such as a timing belt 162 which is a part of
drive system 110 more fully described below. It should be noted
that because of the out-of-balance forces caused by the cam-shaped
lobes 130 of the main roller assembly 100 and the cam-shaped lobes
150 of the snubber cam assembly 102, the assemblies 100 and 102 are
dynamically balanced to allow for high speed rotation of the
components so as to prevent damage to the assemblies 100 and 102
due to the rotational forces. Specifically, the forces generated by
high speed rotation are counterbalanced in order to prevent damage
to the bearings 120, 152 and 154 and reduce vibration which would
occur if the assembly was left in an out-of-balance condition
caused by the respective cam-shaped lobes 130 and 150.
[0047] Still referring to FIG. 2, pivot shaft assembly 104 is
coupled to snubber cam assembly 102. Housing 164 having a flange
165 mounts to main machine wall 114 with screws 166 from the
outside of the wall 114 as shown. The housing 164 and related parts
are slipped through a bore in main machine frame 114 from the
outside because assembly from the inside or other direction would
be practically impossible because of the opposed components from
the back side left-hand signature slow down device as shown. The
housing 164 supports at least one bearing 166 which supports shaft
168. Pulley 170 attaches to one end of pivot assembly shaft 168 and
timing pulley 172 attaches to the other end of pivot assembly shaft
168. Pulley 170 enables shaft 168 to rotate as a result of being
connected to drive system 110, as will be described directly below.
Swing arms 156 and 158 house bearings 174 and 176, respectively,
which in turn support pivot assembly shaft 168. The bearings 174
and 176 allow pivot assembly shaft 168 to rotate while swing arms
156 and 158 remain stationary.
[0048] It should be noted that the bearings described above may be
axially fixed in or on the relevant components in any number at
ways known to those skilled in the art, such as, for example, with
retaining rings or shoulders.
[0049] Now, with reference to FIG. 3 in conjunction with FIG. 2,
drive system 110 will be explained. Motor 178 includes a pulley 180
mounted to a motor output shaft 182. A belt such as a timing belt
184 is properly wrapped around the pulley 180 attached to motor
178, the pivot shaft assembly pulley 170 and main roller assembly
pulley 122 so as to enable pivot assembly shaft 168 and main roller
assembly shaft 118 to be driven in the directions shown by the
arrows in FIG. 3. Any slack in timing belt 184 may be removed with
an internal belt take-up movable assembly idler 186. Timing belt
162 is also properly wrapped around pivot shaft assembly timing
pulley 172 and snubber cam assembly timing pulley 160. Any slack in
timing belt 162 may be removed with an external belt take-up
assembly idler 188. Preferably, pivot assembly shaft 168 turns at
the same rotational speed (rpm) as the snubber cam assembly shaft
138 because the two are coupled together through timing belt 162
and through identically sized timing pulleys 160 and 172. Also,
preferably, pulleys 170 and 122 are identically sized so that pivot
assembly shaft 168 and main roller assembly shaft 118 also turn at
the same rotational speed (rpm). The drive system 110 is configured
such that snubber cam assembly shaft 138 and main roller assembly
shaft 118 turn in opposite directions as shown so that respective
cam members 140 and 124 move in the direction of signature travel.
Thus, the drive system 110 comprises a timing belt and timing
pulley combination. The various pulleys may be provided with any
number of teeth combinations to achieve the results described
herein as can be appreciated by those skilled in the art. In a
preferred embodiment, pulley 180 has 25 teeth and pulleys 170 and
122 have 40 teeth. Such an arrangement increases motor torque as
applied to shafts 168, 138 and 118. In this way, more motor torque
will be applied where it is needed, namely, to the shafts 138 and
118 which include respective cam lobes 150 and 130.
[0050] As shown in FIG. 4, the diverter belt 16 and collator belt
62 shown in FIG. 1 are part of separate groups of belts. Shown are
seven diverter belts 16 and seven collator belts 62. The collator
belts 62 operatively engage with respective tape rollers 132 of
main roller assembly 100 (see FIG. 3). Since the tape rollers 132
attach to bearings 134 (FIG. 2), the belts 62 cause the tape
rollers 132 to freely rotate about main roller assembly shaft 118
irrespective of the rotation of shaft 118. The main roller assembly
cam members 124 keyed to shaft 118 are designed to rotate at a
slower speed than tape rollers 132 as a result of shaft 118 being
connected to drive system 110. The diverter belts 16 travel between
snubber cam assembly cam members 140 which are provided with
sufficient clearance therebetween so that the belts 16 do not
detrimentally contact the sides of the respective snubber cam
members 140. There are eight main roller assembly cam members 124,
seven main roller assembly tape rollers 132 and eight snubber cam
assembly cam members 140 shown in FIG. 2. Preferably, in order to
properly support the signatures between the appropriate belts and
tapes, seven belts and tapes are provided. For every belt or tape
which travels around main roller assembly 100, there is provided a
respective main roller assembly tape roller 132. For every tape
roller 132, there is preferably provided an adjacent cam member
124. However, it is possible to use fewer snubber cam members 140
than there are main roller assembly cam members 124 (see FIG. 4
showing, for example, only five snubber cam members 140). The
snubber cam members 140 can be appropriately positioned along shaft
138 between the respective tapes as previously described. It should
be noted that with reference to FIG. 1, depending on the position
of a slow down mechanism in a folder such as, for example, a front
right-hand located signature slow down mechanism, the collator
belts may travel around the snubber cam assembly and the diverter
belts may travel around the main roller assembly.
[0051] FIG. 5 provides a clearer picture of a signature 190 being
slowed down by a signature slow down mechanism 46. The signature
which is approximately 11 inches long travels through the main
roller assembly 100 and snubber cam assembly 102 unimpeded until
the last three inches or so of the signature. At that point,
snubber cam-shaped lobes 150 of snubber cam members 140 reach out
from between the diverter belts 16 and the main roller assembly
cam-shaped lobes 130 of cam members 124 reach out from between the
collator belts 62 in order to effectively grab the trailing end of
the signature 190 to slow the speed of the signature 190 down.
Since the cam-shaped lobes 150 and 130 of respective cam members
140 and 124 move at a slower lineal speed than the signature 190
and belts 16 and 62, the speed of the signature 190, having been
effectively released by diverging belts 16 and 62 prior to reaching
the signature slow down device 46, is slowed as the slower rotating
cam members 124 and 140 effectively grab the trailing edge of the
signatures 190 with respective cam-shaped lobes 130 and 150.
[0052] Preferably, the signature slow down mechanism 46 according
to the present invention, is designed in such a way that for every
signature delivered from a printing press which travels past the
diverter 20 and down the left-hand collation path 22, the
cam-shaped lobes 130 and 150 of main roller assembly 100 and
snubber cam assembly 102, respectively, turn exactly once to slow
down that particular signature by the right amount. As should be
clear, the lineal speed of the cam-shaped lobes 130 and 150 of
assemblies 100 and 102 is designed to be slower than the speed of
the signatures and the speed of the tapes 16 and 62. The signature
slow down mechanism 46 is designed so that it is in synch with the
printing press and timed properly to the printing press and how
fast the signatures are being made at the printing press. Shafts
118, 138 and 168 turn at the proper rotational speeds so that the
cam-shaped lobes 130 and 150 rotate at the proper speed by
selecting the proper pulley diameters for 122, 160 and 170 and 172,
and the cam-shaped lobes 130 and 150 are made of the proper outside
diameter so that the cam-shaped lobes move at the proper slow down
signature speed. For every two signatures that are printed at the
printing press, one goes down the left-hand side of the diverter 20
and the other one goes down the right-hand side of the diverter 20
and each signature slow down mechanism slows down the respective
signature that travels to it.
[0053] Taking into account a number of variables, the diameters of
cam members 124 and 140 can be determined for a given slow down
mechanism. For a tapes speed gain factor of 13%, a signature having
a length of 10.875 inches and a signature slow down factor of 30%,
the diameters of cam members 124 and 140 should be about 5.5
inches. In a preferred embodiment, the speed of the cam-lobes is
designed to be 20%-40% slower than the signature speed which is
generally the same as the speed of the belts confining the
signature therebetween.
[0054] It should be noted here that, with reference to FIGS. 3 and
5, initially, the cam-shaped lobes 130 and 150 can be properly
aligned generally face-to-face along the signature path by removing
timing belt 184 from pulleys 170 and 122. Pivot assembly shaft 168
can then be rotated until cam lobes 150 are positioned opposite cam
lobes 130. After which, timing belt 184 is repositioned around
pulleys 170 and 122. Once the cam lobes 130 and 150 are properly
aligned, the position of the lobes 130 and 150 with respect to
signature arrival can be adjusted through the use of motor 178 and
the drive system 110.
[0055] Returning once again to FIG. 2 and in conjunction with the
back left-hand signature slow down mechanism shown in FIG. 4, air
cylinder assembly 106 is described. One end of each air cylinder
192 connects to respective swing arms 156 and 158 through a
standard screw, nut and clevis combination 194. A tie bar 196
mounts to main machine wall 114 with screws 198. Although not
shown, the other end of tie bar 196 attaches to another machine
wall opposite wall 114. A pair of stationary brackets 200 mount to
tie bar 196. The stationary brackets 200 and air cylinders 192 are
provided with bores so that a separate pivot pin 202 can extend
through the brackets 200 and the cylinders 192 in order to attach
the other ends of the air cylinders to the stationary brackets 200.
An internally threaded adjustable knob 204 is positioned on each of
the respective rear threaded rod ends of the double rod end air
cylinders 192.
[0056] The air cylinders 192 are provided so that the snubber cam
assembly 102 can be opened or closed as needed. Engaging air
cylinders 192 in one direction or the other causes swing arms 156
and 158 to rotate the snubber cam assembly 102 into or away from
main roller assembly 100 (see FIG. 4). For example, in the event of
a jam, at or near the signature slow down mechanism 46, the snubber
cam assembly 102 can be opened via electronic controls so that the
jam can be cleared away. As another example, it may be desirable to
run a printing press system in which a slow down device is not
needed for the particular product being processed. In such a case,
the slow down mechanism can be moved away from the path of the
signatures so as not to interfere with the speed of the
signatures.
[0057] The air cylinders 192 are provided for another reason in
addition to that noted above. The internally threaded knobs 204,
which act much like a standard nut, control and limit the amount of
extended (forward) stroke of the respective air cylinders 192.
Since the air cylinders 192 are connected to respective swing arms
156 and 158 which are connected to snubber cam assembly 102, by
turning knobs 204, a fine adjustment can be made to the gap between
the two opposite facing cam-shaped lobes 130 and 150 (see FIG. 5).
The adjustment of the nut-like knobs 204 can be locked with a
clamping screw lever mounted on the knobs 204 (not shown) so as to
lock the air cylinders in place. Adjusting the gap between
cam-shaped lobes 130 and 150 ensures that signatures traveling
therebetween are not squeezed too hard which could cause damage or
mar the folded signatures. A certain amount of signature squeeze is
necessary, however, so that the speed of the signatures is
adequately and accurately slowed down as planned, keeping in mind
that excessive squeezing is to be avoided to prevent damage to the
signatures.
[0058] Referring back to FIG. 2, a further aspect of the signature
delivery system 10 is described. Shown is part of a signature guide
assembly 108. FIGS. 5 and 6, show in further detail, other parts of
a signature guide assembly 108. Shown in FIG. 2, housing 206 having
a flange 207 mounts to the machine wall 114 with screws 208.
Housing 206 holds at least one bearing 210 which supports an idler
shaft 212. Idler 212 is shown in FIG. 1 downstream of the snubber
roll 76 of slow down mechanism 46 in the path of the belts 16.
Idler 212 is a grooved roll referred to as a signature eject
roller. Between each groove 214 is a respective raised step 216.
Belts 16 travel within respective grooves 214. The grooves 214 are
wider than the width of the belts 216. Preferably, each groove 214
is slightly crowned so that as a belt 16 travels within a
respective groove 214, the belt does not substantially wander from
side to side between respective raised surfaces 216. The function
of the crown is to keep the belts 16 running in the middle of the
grooves 214 as much as possible.
[0059] As shown in FIG. 1, preferably a second idler roll 218 is
provided to the left and parallel to eject roller 212 also within
the path of belts 16. Idler 218 can be a grooved roll like eject
roller 212 (see FIG. 4) but can also be a smooth non-grooved idler
roll. Idler 218 is provided to share the belt load with idler 212,
the load being generated by belt length variation, belt tension and
belt wrap angle of belts 16.
[0060] Shown also in FIG. 2, is a second signature eject roller
220. The eject roller 220 is shown in FIG. 1 downstream of main
roll 68 of slow down mechanism 46 in the path of the collator belts
62. Eject idler roller 220 is also a grooved roll like eject roller
212. Preferably, so that the eject rollers 212 and 220 can be
positioned as close as possible to the fan delivery device 30, the
diameter of eject roller 220 is smaller than the diameter of eject
roller 212. As the signatures travel through the slow down
mechanism 46 on their way to the fan delivery device 30, it is
desirable to support the signatures as much as possible. By
positioning the signature eject rollers 212 and 220 as close as
possible to the outside diameter of the fan delivery device 30,
there is less chance that the signatures will be damaged as they
enter the fan delivery device thereby reducing the likelihood of
jams occurring in this area.
[0061] FIG. 6 shows the signature eject roller 220 in the greatest
detail. Brackets 222 and 224 are oppositely positioned around
driven shaft 118 of main roller assembly 100. The brackets house
bearings 226 so that shaft 118 is able to rotate while the brackets
222 and 224 remain stationary. The mounting brackets 222 and 224
are connected at one end by tie bar 228 which is attached to the
brackets by screws 230. The brackets 222 and 224 are prevented from
rotation by fixedly tieing bracket 222 to housing 112 of main
roller assembly 100 with a dowel pin or similar means not shown.
Mounted to the other end of brackets 222 and 224 is the signature
eject roller 220 (see also FIG. 5). Eject roller 220 includes
grooves 229 and raised steps 231 which are similar to grooves 214
and steps 216 of eject roller 212. Eject roller 220 can be
positionally adjusted with respect to collator belts 62 depending
on where the brackets 222 and 224 are fixed relative to housing
112. Although not shown, a stationary shaft is positioned through
the eject roller 220. The shaft is attached to brackets 222 and 224
with screws or the like. The eject roller 220 houses a pair of
bearings which allows the idler eject roller 220 to rotate on the
stationary shaft. One or both of the brackets 222 and 224 contain a
slot near where the stationary shaft mounts to the brackets 222 and
224. In this way, when the bearings housed in the eject roller 220
need to be replaced, the eject roller 220 can simply be removed
from the brackets 222 and 224 and then easily returned thereto once
the bearings have been replaced.
[0062] As the signatures travel down through a signature slow down
mechanism, there is a natural tendency for the signature to want to
cling to the transport belts or tapes and follow the belts or tapes
rather than continue on in a straight path to further processing
equipment which may lead to jams in the overall system. The
signature eject rollers 212 and 220 are provided to prevent this
scenario from happening. With reference to FIGS. 2, 5 and 6, the
diverter belts 16 travel in the grooves 214 of eject roller 212 and
the collator belts 62 travel in the grooves 229 of eject roller
220. The respective raised steps 216 and 231 are sufficiently
extended to reach beyond the respective belts 16 or tapes 62. If a
signature attempts to follow belts 16 and/or tapes 62 around the
bottom of eject rollers 212 and/or 220, the raised step 216 and/or
231 will contact a respective side of the signature thereby forcing
the signature from the respective belt or tape. In this way, the
signatures are prevented from incorrectly following the belts 16 or
tapes 62 and the signatures are sent on a substantially straight
course into further processing equipment such as a rotary fan
device 30.
[0063] The signature eject rollers 212 and 220 can be referred to
as rotary signature strippers. The eject rollers rotate at the
speed of the belts or tapes in contact therewith. An advantage of
the rotary signature stripper is that the signature eject rollers
212 and 220 are moving as they effectively strip the signature
thereby causing less damage to the signatures than what a
stationary stripper may cause.
[0064] Also, shown in FIGS. 5 and 6, is an air blowing device 232
which is another component of the overall signature guide assembly
108. The air blowing device 232 and signature eject rollers 212 and
220 may be used in conjunction with or independent of each other.
The air device 232 is positioned downstream of eject roller 220.
The air blowing device 232 is preferably composed of two round
tubes 234 and 236 but may be a single tube fixedly attached to
brackets 222 and 224. One tube 234 is shown in FIG. 6. As shown in
FIG. 5, the air device 232 is positioned adjacent the signature
path of the signatures. The air tubes 234 and 236 preferably have a
row of evenly spaced holes through which air can be blown through.
The air to each tube is independently provided from a source of
pressurized air, not shown, attached to one or more nipples 238.
The amount of air flow and how the source of pressurized air is
attached to the air device 232 is not significant in terms of the
present invention. As shown in FIG. 5, the top tube 234 is
positioned such that air can be blown toward the body of the
signatures and towards the open side of the signatures traveling
past the air device 232 from the signature slow down mechanism. The
bottom tube 236 is positioned such that air can be blown generally
parallel to the direction the signatures travel past the air device
232. The air device assists in guiding the signatures from the slow
down mechanism 46 to the next step in the sheet processing system
such as a fan delivery device 30. The air device also prevents a
folded signature from opening at its open end as the signature is
transferred from the slow down device to the downstream equipment.
If the signature were to open, it could cause a jam of the overall
system.
[0065] Another component of the overall system described thus far
and which may also be a part of the signature delivery system 10 is
a diverging belt or tape adjustment roller 240, shown only in FIG.
5. The roller 240 is mounted to machine wall 114 such that the
roller 240 is adjustable in a horizontal direction generally
transverse to the signatures and belts travel path as shown by the
double arrow. The adjustable roll 240 is preferably provided to
control and modify when the belts 16 and 62 will begin diverging
from a point downstream of the slow down device lead-in roll 66. In
addition, adjustable roll 240 can be used to manipulate the belts
16 and/or tapes 62 in order to assist in preventing a folded
signature from wanting to cock or go crooked as it travels downward
toward opposed cam lobes 130 and 150 of the signature slow down
mechanism 46. As a folded signature travels down the collation path
22 past the lead-in idler roll 66, the signature has a tendency to
want to cock or become crooked between the belt 16 and tape 62. The
folded signature is not as thick on its open side as it is on the
folded side. The open side of the signature tends to want to fall
down quicker than the folded side as the signature travels to the
slow down device 46. The ends of roller 240 can be individually
adjusted generally transverse to the path of the signatures and
belts. As a result, by skewing roller 240, the belt 16 and tape 62
can be caused to grip the open side of the signature more firmly
thereby preventing the open side of the signature from falling
ahead of the folded side of the signature. Roller 240 could also be
designed to be smaller in length than, for example, lead-in roller
66, and positioned in the delivery system so as to only effect
those portions of belts 16 and/or 62 which transport the open side
of the signature.
[0066] As is readily apparent in FIG. 2, the main roller assembly
100, the snubber cam assembly 102, the pivot shaft assembly 104 and
the signature guide assembly 108 are cantilever mounted to the
framework 114 of the folder. The purpose of the cantilever design
is so that all of the belts and tapes used in the delivery system
10 are easy to install, remove and replace. In other words, since a
folder according to the present invention may include four delivery
systems as explained above, the noted assemblies are designed in
such a way that there is a break in the middle of the machine (FIG.
2) so that belts or tapes can be easily inserted, removed or
replaced between the front and back delivery systems as needed.
[0067] In another embodiment of the present invention, sensors (not
shown) are provided upstream of the slowdown mechanism 46 and
preferably near idler lead-in roll 66 to sense the location of the
leading edge of the signatures as the signatures are delivered to
the slow down device 46. The sensors may be any type of sensor
known to those skilled in the art designed to indicate the position
of a moving article such as, for example, a through-beam sensor or
an infra-red sensor. Signals from the sensors are delivered to the
motor 178 to control the operation of the motor 178 which controls
the drive system 110. Signals from the sensors can be provided to
the motor 178 such that the cam members 124 of the main roller
assembly 100 and the cam members 140 of the snubber cam assembly
102 can be properly positioned such that the respective cam lobes
130 and 150 grab the trailing end of each signature traveling
through the slow down mechanism 46. If the cam-lobes 130 and 150 do
not properly grab the trailing end of the signatures, the motor 178
can be advanced or retarded so as to correct the position of the
cam lobes 130 and 150.
[0068] The same sensors can also be used to send signals to the
motors (not shown) driving the fan delivery system 30 such that the
appropriate slot in the fan delivery system is positioned to
receive the signatures as the signatures are delivered to the fan
delivery system.
[0069] The motors of the slow down devices and the motors of the
fan delivery devices can be phased so as to provide for optimum
delivery of the signatures through the slow down devices and to the
fan delivery devices.
[0070] In general, with reference to FIG. 1, considering what is
shown in FIG. 5, signatures travel in tandem down the diverter path
14. All of the signatures are moving at approximately the same
speed and they are following each other one behind the other with a
gap of a predetermined distance between them. As the signatures
approach the diverter 20, one signature will go down one collation
path 22 and the next signature will go down the other collation
path 24 and so on. Before being diverted, the signatures have a
space between them equal to about 1-2 inches. As the signatures are
diverted, the space between each signature grows by the length of
one signature plus another 1-2 inches because every other signature
is directed down a separate collation path. Downstream of diverter
20 is a signature slow down mechanism 46. A front leading signature
approaches the slow down mechanism 46. A second following signature
that has not yet reached the slow down mechanism 46 is traveling
still at the original speed. Since the first signature is slowed
down by the slow down mechanism 46 as it travels through the slow
down mechanism 46, the gap between the two signatures is shrinking
at a very fast rate and there is a possibility of a collision
between the signatures if the gap becomes too small. In other
words, if the front signature is slowed down too much, the
signature that is following it could crash into it. Because of the
diverter 20, which sends every other signature to a different
location, the space between the signature becomes larger by one
signature length and one gap space and therefore you can slow down
the front signature more than you could without the diverter
20.
[0071] The foregoing description of the present invention has been
presented for purposes of illustration and description.
Furthermore, the description is not intended to limit the invention
in the form disclosed herein. Consequently, variations and
modifications commensurate with the above teachings in skill or
knowledge of the relevant art, are within the scope of the present
invention. The embodiments described herein are further intended to
explain the best modes known for practicing the invention and to
enable others skilled in the art to utilize the invention as such,
or other embodiments and with various modifications required by the
particular applications or uses of the present invention. It is
intended that the appended claims are to be construed to include
alternative embodiments to the extent permitted by the prior
art.
[0072] Various features of the invention are set forth in the
following claims.
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